Process for making brake-shoes.



I. K; GA SWBLL. PROCESS FOR MAKING BRAKE SHOES.

AllfLIOATIOI FILED DBO. 17, 1906.

Patented Oct. 18,1910.

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P. K. GASWBLL. PROCESS FOR MAKING BBA KE SHOES.

Patented Oct. 18, 1910.-

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APPLICATION FILED DEO.'17, 1906.

Patented Oct. 18, 1910.

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F. K. GASWBLL. PROCESS FOR MAKING BRAKE SHOES.

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UNITED STATES PATENT OFFICE.

FREDERICK K. CASWELL, OF LOS ANGELES, CALIFORNIA, ASSIGNOR TO PAUL'DICK-INSON (INCORPORATED),

OF CHICAGO, ILLINOIS, A CORPORATION OF WYOMING.

PROCESS FOR MAKING BRAKE-SHOES.

Specification of Letters Patent. Patented Get 18, 1910.

Application filed December 17, 1906. Serial No. 348,173.

To all whom it may concern:

I to it known that I, FREDERICK K. CAswnLL, a citizen of the UnitedStates, residing at Los Angeles, in the county of Los Angeles and Stateof California, have invented certain new and useful Improvements inProcesses for Making Brake-Shoes, of which the following is a full,clear, and exact specification.

My invention relates to improvements in brake shoes for railway trainsand the like and has for its primary object to provide an improvedmethod of constructing brake shoes whereby I secure a more efficient andeconomical brake shoe than heretofore produced, and securing at the sametime efficiency and economy in manufacture and at tain a certain degreeof uniformity of procluct which I find very desirable.

To the attainment of these ends and the accomplishment of other new anduseful objects, as will appear, my invention consists in the features ofnovelty in processes hereinafter more fully described and claimed andillustrated in the accompanying drawings in which I illustrate one meanswhich may be employed in carrying out the processes embraced in myinvention, and in Figure 1 is a plan View of an assembled mechanismemployed in producing a complete brake shoe by my process. For thepurpose of greater clearness in referring to the other figures I dividethe mechanism as illustrated in Fig. 1 into sections designated by theupper case letters A, B, C, D, E, F

and G. Fig. 2 is a side elevation of mechanism designated by section Ain Fig. 1 and is taken on line 2-2 Fig. 1. In this figure a portion ofthe base plate on which the machine rests is broken away in order toshow the manner of adjustably attaching the same thereto. Fig. 3 is aside elevation of mechanism designated by section B and is taken on line3-3 Fig. 1. Figs. 4; and 5 taken together, illustrate a side elevationof mechanism indicated by sections 0, D and E Fig. 1. These views aretaken on line 4lt of Fig. 1 and Fig. 4 has parts of sections C and Dbroken away to show the interior construction. Fig. 6 is an eleshoeafter the same has passed through stamping or punching press indicatedby mechanism in section A, Figs. 1 and 2. Fig. 8 illustrates the samematerial after passing through forming or bending dies carried by themechanism in section B, Fig. 3. Fig. 9 is a sectional view on line 9-9,Fig. 8. Fig. 10 is a sectional view on line 10.l0, Fig. 8. Fig. 11illustrates the succeeding operation, that of entirely severing theholder or shell blank from the original sheet. Figs. 12 and 13 aresectional views on line 12-12, and 1313 respectively, Fig. 11. Fig. 14;illustrates the holder or shell after the operation of bending the sideand end members in order to prepare the same for the reception of thefilling material. In the present embodiment of the invention theoperations required to produce the shell as it appears in Figs. 11 and 11 follows im mediately the operation on the same in secvtion B, bothoperations are produced by the double acting punching and formingmechanism in section 0, Figs. 1 and at. Figs. 15 and 16 are sectionalviews on lines 15-15 and 1616 respectively of Fig. 14.. Figs. 17 and 18are elevations in plan view of one form of the filling material or bodysubstance to be inserted in my shell or holder at the stage ofcompletion the same as illustrated in Figs. 14, 15 and 16. Figs. 19 and20 are plan and elevation views respectively of a complete brake shoemade by my improved process.

In the following description of the steps employed in producing my brakeshoe I illustrate fully and make constant reference to the mechanismthat I prefer to employ, although it is evident that this mechanism maybe greatly varied in any or all of the steps performed by simpler andmore crude means than I employ, and many of the steps infiy even beperformed by ordinary hand a or.

I make no claim in this application to the specific mechanism employedas the same is the subject of other applications for Letters Patentfiled by me of even date herewith. a

10 is a bed plate on which is adjustably mounted a series of mechanismsindicated by sections marked A, B, C, I), E, F and G respectively onFig. 1. This plate is provided with a series of slots 11 adapted to takeretaining bolts from various mechanisms mounted thereon. The group ofmechanism represented by the letter G refers to means of producing powerfor driving the associate mechanisms. The mechanism embraced in sectionA, illustrated more fully in Fig. 2, is adapted to receive material forforming the holder or shell of my brake shoe in the form of elongatedstrips or blanks. These blanks are preferably of the required thicknessfor forming the shell and of a width to correspond approximately to thelength required to make the completed shell. This material may be fed tothe machine in strips of any desired length, although for convenience inhandling, I prefer to have the material come from the mills in stripsabout 20 ft. in length. A portion of one of such strips is indicated by40. Suitable feeding mechanism may be employed in connection with themechanism in section A, as for example, the movable jaws 12, to grasp abar or strip of this sheet metal and feed it longitudinally through themechanism in the direction indicated by the arrow in section A. Suitablecutting or punching dies here act upon the metal producing a series ofcuts or slits in distinct groups each group of such cuts or slitsadapted to blank out the material to be embodied in a single shell orholder and consisting of the elongated side slits 41 and 42 which extendat approximately right angles to the length of the strip but are not cutentirely through the strip at the ends thereof. This manner of blankingout the holders preserves the entire strip of material intact so that itmay be fed farther through the machine for succeeding operations.

By reference to Figs. 7 to 16 inclusive it will be seen that slits orcuts 41 and 42 determine the width of the completed blank for formingthe shell. The irregular slits or cuts 43 to 54 inclusive extendlongitudinally of the shell or blank midway between the slits 41 and 42and are for the purpose of providing means for attaching the brake shoeat its back to the brake block or head. Cuts 43, 44, 45, 46, 47 and 48surround members 43 44, 45, 46, 47 and 48 respectively. These lastmembers are all adapted to bend or form outwardly from the back of theblank for the purpose of forming members at each end of the shoe to takeboth endwise and lateral strains. Cuts 49 and 50 form members 49 and 50which are like wise adapted to be bent outwardly to form metal supportsin attaching the brake head. The rectangular holes 51 and 52 formmembers 49 and 50 for the purpose of taking ordinary retaining key orpin used on the common Christy or M. C. B. head. It will be seen thatthe various cuts performed on blank shown in Fig. 7 may be made at oneoperation of the punching die carried by the mechanism in section A.

It will be noted that this mechanism performing the first operation onthe blank is a double headed single acting press in which the movableheads 13 and 14 are adapted to carry the dies.

In Fig. 2 a section of bar 40 of sheet metal is shown in position infeeding mechanism. The die or dies for performing this operation andtheir cooperating members are not shown. It is evident that a singleheaded press may be used as well in performing this operation for thereason that it is a simple punching operation and as no bending out ofthe planes of the sides of the material takes place while the materialis in this mechanism it may readily be disengaged by the feedingmechanism in order that it may be passed on to the next mechanism forfurther treatment. After the sheet of material receives the cutsillustrated in Fig. 7 it is next passed by feeding means to themechanism illustrated in Fig. 1 section B as also shown in enlarged formin elevation in Fig. 3. This mechanism as shown is a duplicate of thedouble headed press described in previous operation and it is alsoprovided with feeding mechanism containing jaws 12 as illustrated inFig. 1. During the passing of the material through this mechanism it isacted upon in the manner indicated in Fig. 8. It Will be noted that theprocess is entirely one of'forming or bending of the members 43 to 50inclusive at approximately right angles to the plane of the blank asindicated more clearly by reference to Fig. 9. All of the last mentionedmembers it will be noted, are bent outwardly from the blank on the sameside thereof and on the side which afterward becomes the back side orthe outside of the shell. It will also be noted that in this mechanismmembers 53*, 53 54 and 54 are formed outwardly from the plane of theblank but on the opposite side of the blank from members just mentionedand on the side that afterward becomes the inner side of the shell. Itwill be noted that this operation leaves the shell blank still intactwith the material in sheet form and that to perform this operation ofbending it is necessary that the double headed form of press be employedin order to free the sheet of material from contact with the dies as thesurface of the material is no longer smooth as it was after the firstoperation. In the mechanism shown in section B, Figs. 1 and 3, numerals15 and 16 indicate the movable members of the press which carry theforming dies corresponding to parts 13 and 14 in mechanism section A.From the mechanism just described, the blanks still intact in theoriginal sheet are fed onwardly to the mechanism indicated by Figs. G,D, E and F. The sheets first enter mechanism indicated in Fig. 1,section G shown also in enlarged elevation in Fig. 4 where they arefirst seized by feeding mechanism similar to that already described andindicated by the;

grasping jaws 12, section C, Fig. 1.

By reference to the mechanism in section C, more particularly, theenlarged view in Fig. 1- it will be seen that the material is acted uponby single headed double acting press. The movable member indicated bythe numeral 17 may carry a cutting tool for performing the firstoperation on blank in this section as illustrated in Figs. 11, 12 and13. This operation it will be noticed consists in entirely severing theblank from the metal sheet and continuing the elongated slots 11 and 42toward the sides of the sheet terminating at corners 55 to 57respectively, where each slot makes a rightangle turn extending in thedirection of the opposite slot, forming the connecting slots 59 and 60and enlarged slots 59 and 60 and the diametrically opposed andinwardlyextending branches 59*, 59, 60 and 60. The cutting operationjust described, results in severing the blank designated by the nu-.meral 61, Figs. 11 to 16 inclusive, and before the cutting die iswithdrawn in order to prevent the release and displacement of the blank61 from the position in which it is held by reason of the contact of thetool carried by head member 17 which forces the T tion F, lug.

blank against supporting member 18, bend ing or forming die carried 011movable members l9 and 20 moves forward and firmly holds the blankagainst supporting member 18 thus allowing the cutting die carried onmember 17 to be withdrawn. The action of the forming die or tool carriedon members 19 and 20 is continued, thus crowding the blank into formingmeans on member 18 bending outwardly into position the side membersindicated by the numerals 62 and (33, Figs. 14 and 16, at the same timethe end members indicated by numerals 64 and 65 Figs. 14; and 15 areformed outwardly into position from the plane of the blank. During thisoperation the shell blank is crowded entirely through member 18 by theforming tool and placed in the position indicated by the shell 61 shownin dotted lines on turret wheel 21, Figs. 1 and 5. The forming toolwhich has accomplished the result of placing the shell in position onrotating wheel 21 is then withdrawn, movement is imparted to wheel 21 bywhich it is caused to rotate in the direction of the arrows as indicatedin Fig. 1. Before another operation is performed on the shell it iscarried by the wheel 90 degrees, thus placing it in position to receivefilling material or body from mechanism illustrated by sec- 1, whichmechanism is also shown in enlarged elevation View in Fig. 6.

As a body or filler for the shoe, various vegetable and mineralsubstances and com positions have been used and with varying success. Inorder that the completed shoe may have the proper frictional qualitiesin contacting with the moving surface on the wheels, material of greatfirmness is required. I prefer to use vegetable fiber, preferably wood,of the common varieties but ordinarily belonging to the classes of thehardwoods. This wood I previously treat by various well-known processes;driving the vegetable juices therefrom and impregnating the fibroussubstance with carbon oils. Before being presented to the mechanism insection F blocks of previously treated wood are given the shapeindicated by numeral 70, Figs. 17 and 18.

The mechanism in section F will be more fully described and is alsoclaimed in application for Letters Patent of even date herewith. It isdesigned to compress block '70 laterally to one-half its width and asillustrated in Fig. 18, it is approximately double the width of theinterior of the shell as illustrated in Figs. 14, 16 and 19. It will benoted that the shell 61 has not yet been given the necessary curvatureto correspond with the curvature of its contacting surface on the carwheel, although by reference to the holder form 22 Figs. 4 and 5, itwill be seen that the form itself has the requisite degree of curvature.The mei'nbers 23 and 24 which hold the shell by grasping the members 49and 50" on the back of shell are elastically mounted in order that theymay withdraw toward the convex side of the curve of this form when it isdesired to give the shell its proper degree of curvature. This I preferto accomplish at the same time the filling block is inserted by themechanism in section F. Movable members 25 and 26 in section F areadapted to perform the described operation of compressing the wood whichthey do by acting in conjunction with the fixed member 27. After theblocks are compressed they are grasped by suitable feeding mechanism, asfor example, the reciprocating members 28 and 29. I prefer to make thesereciprocating members of sufficient strength to permit of very firmpressure being applied thereby in inserting the filling blocks into theshell. The convex face of the block is first presented to the shell, andafter being inserted sufiicient pressure is applied to cause the shellto assume the proper degree of curvature to corre spond with the fillingblock, which degree of curvature is also approximately the same as thatof the. shell holding block or form 22 previously described.

In construction shown it will be noted that I employ a double headedpress for compressing the filling material which makes it necessary toemploy the double inserting mechanism 28 and 29. These insertingmechanisms work alternately, one

tools of similar construction referred to in section G is employed. Thisconsists of what may be termed a single headed double acting press. Thereciprocating head or ram 30 actuates suitable mechanism for compressingthe side members 62 and 63 in order to cause them to contact closelywith the filling material. These side members of the shell, as theyleave the mechanism in section C, are not quite at right angles to theback of the shell. The action of the forming mechanism in section 0 willbring them to the right angle position but the elasticity of the metalcauses them to spring apart slightly which is of value in the process inpermitting the insertion of the filling material. By referring to Fig.11 it will be noted that in the operation of severing the shell blankfrom the sheet material auxiliary end members 66 to 69 inclusive wereformed. The position these members assume after the process of foldingthe sides and ends of the shell, is shown by referring to Figs. 14 and15. Immediately after the operation just described, of closing the sidemembers 62 and 63, and before the pressure is released, the secondsection 31 of the reciprocating member or ram actuates suit-able bendingand compressing mechanism to fold members 66 and 67 inwardly and aroundend member 64 and members 68 and 69, likewise around end member 65. Theposition of these parts on the completed shoe is shown by reference toFigs. 19 and 20. This operation completes the shoe and it is thencarried by the turret wheel 21 from contact with the mechanism which isdescribed in section E and may be discharged at any convenient pointbefore it is carried by the revolution of the turret to a point injuxtaposition with the mechanism in section C. Any convenient form ofreceiving and conveying mechanism, as indicated diagrammat-ically by 32and 32*, may be employed for this purpose.

Any desired number of inwardly eXtending barbs similar to 53 53 54 and54 may be employed. The material is impaled on these barbs at the timeof its insertion in the shell by the mechanism in section F. Thisconstruction assists in retaining the filling material more firmly inthe shell and is a feature which is particularly desirable on account ofthe adaptability of a brake shoe of my construction to withstand wearuntil the filling material and sides of the shell have been practicallyworn away.

75 (see Fig. 1) is any convenient form of holding device or mechanismfor retaining a quantity of sheets of material for insertion in themechanism and between feeding jaws 12.

7 6 is the main frame upon which mechanism section A is mounted. 77 is asimilar frame carrying mechanism in section B.

The frame for carrying mechanism in sections C, D and E may be integralas indi cated in 78, or the mechanisms in these sections may be carriedon separate frames if desired and secured by attaching them to eachother and to bed plate 10.

7 9 is the frame supporting mechanism in section F and is somewhatsimilar in construction to 76 and 77.

80 is shaft mounted on frame 7 8 transmitting power to the entiremechanism through spur gear 81 which is geared into 82 mounted on shaft83 imparting motion to mechanism in section F.

82 also meshes with spur gear 84 mounted on shaft 85 which shaft passescontinuously through sections A and B, as will be seen by referring toFig. 1.

Cam 86 mounted on shaft 85 imparts reciprocating motion to member 87 andwhich in turn acting on members 88 and 89 and segmental bell crank 90gear 91 and any suitable rack and pinion movement imparts reciprocatingmovement to shaft 92. Shaft 92 may extend to mechanisms in sections A, Band C thereby actuating feeding mechanisms of those sectionssynchronously.

By reference to Fig. 3 the form of mechanism I prefer to employ forreciprocating the two carrying heads or rams in various presses will beseen. 93 is an eccentric cam on shaft 85 imparting reciprocating motionto member 94 which imparts movement to member 15 through links 95 and97." Link 97 may be adjustable by turn buckle 9'7 for the purpose ofmaking slight adjustments. Mechanism for operating member 16 includeseccentric cam 98, reciprocating member 99, links 100 and 101 and lever102, similar to that just described.

Mechanism employed in Fig. 4 for actuating double acting press issimilar to that just described including cams 108 and 104, reciprocatingmembers 105 and 106, links 107, 108, 109 and 110, and levers 112 and113. Eccentric cam 114 (see Fig. 5) and reciprocating member 115 areadapted to impart motion to turret or carrying wheel 21. This may beaccomplished to link 116, reciproeating lever 117 and any convenientform of construction connected thereto as for example, familiar pawl andratchet mechanism 118 represents the axis on which turret wheel 21 isrotated; ball bearing or other antifriction means as indicated at 119may be employed. Gear 120 carried by shaft 80 meshes with gear 121thereby actuating cam 122. This cam acting on spring controlledreciprocating member 123 and connecting link 121 controls stop 125 whichis provided for the purpose of checking turret wheel 21 at predeterminedintervals thus presenting the holding and forming members 22 mountedthereon to the mechanisms in sections C, F and E in the proper relation,in order that the heretofore described operations may be performed onthe materials carried by the wheel. Bell cranks 126 are acted upon bymember 31 in manner previously described and carry the tools for foldingthe auxiliary end members of the shell, and members 127 carry the toolsfor finally compressing the sides of the shell, both of which operationshave been previously described.

The eccentric cams 128 (see Fig. 6) pass reciprocating motion to members129 and 130 which in turn actuate members 28 and 29 through links 131and 132, segmental gears 133 and 134, toothed pinions 135 and 136-andracks 137 lar to that previously described for actuating the feedingmechanism section A. Rams or heads 25 and 26 are actuated from shaft 83by mechanism similar to that previously shown and described, (see Fig.3).

' In order that the invention might be fully understood, the details ofan embodiment thereof have been thus specifically described, but

lVhat I claim is 1. The herein described art or method of making brakeshoes having a filling or body of frictional material incased in a shellor holder formed of sheet metal, which consists in providing a shellblank with integral back, side, and end members, folding said side andend members at an angle to the plane of said back member, insertingwithin the shell or holder thus formed while and 138, movements similheld within the matrix a filling block of frictional material, undersufficient pressure to give said shell the curvature necessary tocorrespond with the braking surface of a car wheel, and closing the sideand end members by folding them inwardly on said filling.

2. The herein described art or method of making a brakeshoe, whichconsists in inserting a body of filling material of high frictionalqualities, formed with two of its opposite faces curved concentricallyto correspond to the braking surface of a car wheel, in a holder orshell of sheet metal embodying a back member, side members and endmembers folded at an angle thereto, and auxiliary end members integralwith said side members, and causing the shell or holder to conform tothe surface of the filling material by using the same as a die block orformer to impart its curvature to the back of the shell and afterwardsecuring the side members, end members and auxiliary end members, byfolding and compressing them inwardly to contact with sides and ends ofthe filling material.

3. The herein described art or method of making brake shoes having afilling or body of frictional material incased in a shell or holder ofductile material, which consists in providing a body or block of fillingmaterial of the form desired in a completed shoe having a curvilinearfrictional surface and a back. surface approximately concentrio with thesaid curvilinear frictional surface, and afterward using said fillingmaterial as a die block or former to produce a corresponding curvilinearshape to the back member of the shell or holder by inserting the fillinginto the shell under pressure while the shell is held in a matrix orform.

In testimony whereof I have signed my name to this specification, in thepresence of two subscribing Witnesses, on this 11th day of December A.D. 1906.

FREDERICK K. CASVVELL.

WVitnesses:

M. W. OANTWELL, A. L. SPRINKLE.

